Sears Free Spirit 298.488531 User manual

IIIII I
SPORTS CENTER
MODELNO.
298.488531
• contents
• Installation
• operation
• adjustment
• maintenance
• replacement parts
p
OWNER,SMANUAL
: II IIII] I
=L
L•
Publication No. 970-36151-202

E
M .............. 1
SPECJFi_oNs:'_!i_.:_:;:_-...:..:i..........!!;_:.,_;;i_!-:.:._:i.;::............ 2
. = ,-. ,.,o . . . ° . ,= . o.o . = = o
°°°°=°°°°6. 6
°.==°.o.°°. 9
lO
...... . ...... 11
12
.... _...... ;. 13
.... _........ 13

MAJOR PARTS
.=
(10) ROLLER ENGAGE
(9) CLAMP BRA(
(8) RUBBER
" (7| SUB MUFFLER
(15) THROTTLE
(14) MUFFLER BODY
(13) DRIVING
o • -o
AIR :CLEANER
12) FUEL TANK
16) MOTOR STOP SWITCH
(21) ENGINE
(17) CHOKE LEVER
(20) PRIMER (18) FUEL LEVEL GAUGE
(19) CLAMP BRACKET
• _ ••i• i •• _,•_ii¸

SPECl FICATIONS
MODEL NO. _ ;,.i::,.
TYPE ; : : i::_i:
PISTON DISPLACEMENT
'COMPRESSION :,RATIO
OUTPUT (MA XIMUM) !i
., ,.,...........
DRMWEIGHT-:--_":_ .....-::_/:i!i::5!5k_s!('.12:0:l_b_):[i(MotoronlYl '";::;!(::.:'i:_:4:-/. "............
CARBURETOR :_'?' [L: 'iPaten'te_J_;R_iary:Typeti(Auiomatic Choke}'
STAi_i:iNG sYSTEM : Ru'bb_#-Roiier Dri_te (_ears#648859) :;_:
FUEL _CONSUMPTION :68 I<_P_r:iiitei_igasli;(i60 Mites/US Gal,) ":i ....
FOEI_ :TANK : CAPACITY" !1;OL,::(0!2B:LjS Gai:il : ;_
FUEL MIXTURE RATIO 25 parts regutar gasoline to 1 part two-cYcle oil
MAXIMUM SPEED 32km/H (20MPH) :
ALL DATA SUBJECT TO CHANGE W:[THOUT NOTICE.
PtRIT-i6 c¥c,EASSISTMOTOR be
:'installed on any standard bike in minutes.' The motor
mounts on the fr0nt fork of the bike,:and transmits
power from the driving roller to the front wheel. The
!_ _motor speed isfinger-controlled by the throttle lever (15).
Rais!ng the roller engage lever (10} wil! lift the roller
off _the tir e, giving you the choice of operating as a
:bicycle,'.or asa motor bike, without ever dismounting to
do eitfter: _
DEPENDABLE MOTOR
:•liThe utter reliability and extreme.light weight of this
;i.motor:ate the result of years of engineering experience,
?ii_andguarantee dependable service under all circumstances.
2
J:

HANDLING
Because of the ease of installation, and simplified con-
trois, the motor can be used on every type of bike, from
aten-speed racer to a three-wheeled adult tricycle.
ECONOMICAL _:"-
The motor runs up to 160 miles_per gallon (MPG) at an
averagecruising speed. . •
GREAT PERFORMANCE... PEDAL,- OR POWER
Since the moto_mounts on-yOur_own bike, a bike suited
to your needs, you have the best of two worlds. Motor
off, your. bike performs as_welt as it always did. Motor
on, you've added a wonderful new dimension to cycling,
without sacrifice.
UNIQUE CARBURETOR:.. AUTOMATIC •:CHOKE!
With=the: throttle lever closed, the carburetor choke is
._aut0matically activated, with nothing to fiddle with, as-
spring you of quick and easy starts. As you move the
throttle lever to.higher speeds; the choke turns itself
off at the "proper.time, without your having to even think
about it_i Patented; _of co_rse, There is=another choke
lever (][:1:).-but this is for useonly when the temperature
is extremely cold. "_:-j:_
FUEL LEVEL GAUGE
F:rom the slit on rear side of the engine shroud and
through the half transparent fuel tank •wall, the. fuel
level can easily be observed (18).
NOTE: To pour the fuel, keep front tire=and engine
straight ahead and fill fuel only up to the maxi-
mum level in the filler hole with this. position.
After pouring; close Tank Cap tightly.
I-!
I-3
INSTALLATION
a. First, remove the clamp stay (A&B KEY NOs31 and
33° FIG. 3 on Page 10) from the clamp bracket (A&B
KEY NOs 2 and 32, FIG. 3 on page 10), ([-2)
b. Hold the clamp brackets with both handsand placethe
motor unit on the front tire and clamp the front fork
loosely by the clamp stay (A&B).
c. Push the roller engagelever down all the way. (][-4)
d. Unscrew the front axle shaft nut (6), put the sub muf-
tier stay (KEY No. 2-23) onthe axle and replace the
bxle Shaft nut loosely. (I-5) Then, connect rubber
joint (8).
e. When size of the bicycle wheel is !ess than 23 inchs,
Iongger side of sub muffler pipe should be shortened
to fit. This can be accomplished by cutting with a
steel saw.
f. Apply recommended air pressure to tire. ;
g. Keep the clearance between the driving roller and tire
approximately 4mm(1/6 inJ by adjusting wing nut
on adjusting rod (5). Or you "mayuse thickness of the
• enclosed spanner (KEY No. 1-61) to get rough idea of
the clearance. (I-6) For riding on wet surface, smaller
:_ :_clearance then 4mm will help avoiding slipping of the
driving roller. " ....
3

h. Make sure no part of the motor touches the fender or
tire. Tignten screws on the clamp brackets A & B.
i, Tighten axle shaft nut (6), Connect sub muffler (7)
with rubber joint (8) and attache spring clips. ([-7)
j. Install throttle lever in convenient position on bicycle
handle bar. (1-8)
STARTING INSTRUCTIONS
1. BEFORE STARTING
The motor uses a fuel mix of 25 0arts regular gesoline
to 1 part two-cycle oil. The fuel shouldbe premixed
prior to pouring into the fuel tank (12), Itis recom-
mended that a quality two-cycle oil be used in the
fuel mix. Failure to mix oil wi_h gasoline will result
in seizure and severe damage to the motor.
2.
." _ :,'NOTE:
STARTING OPERATION
a. Before starting, push knobbed area (A) of Primer
Pump (20) several times by finger, until Fuel gets to
• Carburetor.
b. Push down the roller engage lever.' ([-9)
c, Push the throttle lever away from you (closed posi-
tion).
d. Pedal the bicycle at proper speed.
e. Pull the roller engage lever up to start the motor.
When the motor is cold, the throttle lever must be
placed at fully closed position for the carburetor's
pump:up action.
f. Keep pedaling until the motor starts,
NOTE: For the first run, a little longer pedaling
would be required n order to pump gas
into the carburetor.
g, After the motor starts, gradually open the throttle.
NOTE: As the motor has been equipped with the
choke-less carburetor,;the motor will start
if'the throttle lever is-positioned at idle.
For starting in cold weather, a little longer
pedaling is required_ ,When extremely cold
use special choke lever (17).
3. DRIVING INSTRUCTIONS
a, The bike speed is controlled by ithe throttle lever.
On the throttle lever there is als0 a "red" motor
stop switch (16) which wil! turn the. motor off
in a_qy position.
b, When climbing a steep hill some pedal-assistance
from you may be necessary, Use your bike's lower
gears if necessary. Remember, mopeds also need
assistance on steep hills, but they don't have the
gears you probably have on your own bike.
c. When slowing down, reduce speed with the throttle
"or disengage the driving roller off the wheel. In an
emergency stop, just use.your brakes hard, and the
motor will stall itself, Drive carefully at all times•
,d. To re-start after a sudden stop, just follow regular
starting procedures.
e, When going down a long slo;3e, do not use,engine
brake. Disengage the driving roller.
f. On bad. roads, or going cross-country, operate the
motor at- moderate speeds, foi" your own safety,
and the protection of the mo,:or.
4
PRIMER PUMP
/
./
/
1-8 I-9
4. MOTOR SHUTDOWN
Returri' throttle lever to idle and depress "red" mot,
stop switch
MAINTENANCE AND ADJUSTMENT
SPARK PLUG
Always use the recommended spark plug (NGK BM-6
or the equivalent) and occasionally check the plug g_
which should be 0.6mm (0.023 _ 0.025 in.). Und_
normal circumstances the electrodes should be perfectl
dry and light brown in col or. If the electrodes are covert
with carbon or oil, the plug should be cleaned; either
solvent or by sand blasting. Be sure to remove all sotver
or grit before reinstalling the spark plug, ([-t0)
GOOD 0m
WRONG
2 0,025 in
WRONG SCRAPE 'OFF CARBON
TIRE INFLATION I--lO
DECARBONIZING -"
• When the exhaust port:of the cylinder and exhaust ope_
ing of the muffler or piston are found carbonized an
narrowed after 10ng use, the motor tends to give insu
ficient power, tt is very important that. the exhaust pc4
of the cylinder and exhaust port of the muffler are ctear
ed with utmost care. This ,should be done at least aft(
every 50hour's operation.

IGNITION, TIMING_ ._,_,:j.,:,,:_,' ,, ............... .,.
•pismantle,_the_ engin.e shroud, then _remo_/e' the _bracket
cover and the fan case from the •motor, and observe the
mark °'M" on the circumference of the magneto flywheel.
The letter "M" denotes "IGNITION TIMING". When
the letter "M" lines up with mating line stamped onthe
crankcase, the contact points should be opening, The
ignition timing should be adjusted by turning the contact
breaker base plate. If the two locking screws on the
plate towards the.right. ::. .........
b. When retarding the timing, turn the base plate towards
the left. (Lll & 12)
I-11 _--
CONTACT BREAKER POINTS _'
•It is necessary to remove the engine shroud, the fan case
and the magneto rotor prior tro adjustingth-e_contact' ..:_.-.............
points. The point gap should be settO0.35mm (0.013in.)i.'ii"::;i"i_:""
at maximum opening. If the contact points are burnt or. _ ..........
pitted, they should be lightly ,filed _with a pointf!le o[.:-_,. :_;_:_,.-
fine sandpaper, if an oil film is_noted on the pointsur-_,_i'oii_.i_ ii_.
face, they should be wiped with a clean rag. '":- ,'_-: - s;: ._.:_-;
NOTE: Always reset the -contact pointsafter filingor /:":_-.._._
dressing to the recommended gap (0.35mm or
0.013 in.). If a deviation of more than 5 degree is .-:
O.35mm - _'_
(O.013 _n.)_
noted when lining the ._'M"_markWith the mating .... " :_"_:_:_]['_'12 _` _'- " 1--13
Sine, the contact poihts'mu'_t be:_replaced_. (L13) -_'_.!._:_.___-_-_:,._..,,_.._.._,._,,.,_, .,_.,,,_ .
Th'is type of carburetor is used On equipment which may _;::' t__J: ..:..-:- ._, .-.: :I_ I
occasionally be operated at various angles and with the ; .... (-_N= :._ _
fuel tank position below the level of carburetor to prevent _;._".= !-:.:, ,.'_ "I _
gas leaking or carburetor flooding. This is one of the most _ / |
advanced, yet simply constructed and most reliable carbu- ° li_ '_ _.___IDLE ADJUSTMENT I U_i
retors on the market today.i The carburetor is Used in - i: _: _ SCREW ..I I._
conjunction with a diaphragm type fuet pump to assure a.... _i.! _ J i '"'" _i I_
constant flow of fuel and steady .motor performance. 5 . ;_ 1. Turn;ngto the right increases..: -_r It
h" ,, " ,, ....... " _-=--_ " Iowest enginespeed ..'_--_*_
T,s carburetor also features SERVICE FREE oper- --- " .
ation with servicing generally being limited to cleaning of 1-14 2. Turning to theleft decreases
lowestenginespeed
the fuel passages only. (I-t4 & 15) .......... ..
,.A!Rc LEANER
AIR CLEANER
The carburetor is suppli_:l with ahigll efficiency type .... CLEANER
reusable sponge air filter. When the,filter element be: _
comes clogged, the motor may fail to start or run in an
overrich fuel condition which greately recluces the power. AIR CLEANER
The filter element should occasionally be cleaned by _, COVER
washing in warm soapy water; completely drying and
reinstalling in the case. (I-16) 1-16 1-17
NEVER RUN MOTOR WITHOUT AIR CLEANER.
GEAR CASE LUBRICATION
After every 100 hours of operation, it:is important that a
good quality grease be added to the gear case. (1-17 &18) °,
DRIVING ROLLER . :°:° "
To remove roller, first.dismantle the engine shroud, then
unscrew the roller fixing nut clockwise with the wrench.
No. 48859 Roller should normally be replaced approxi-
mately every 500 miles.
1--18 1-19
5

F(_R LOOSI
b. >air pressure agrees with that re-
comended 'tire:
c; Check tires for worn out tread.
d. Check for Iooseparts especially around the front fork
The fi te +_I ent of the a_r cleane.r-snoulu_o.ucds:_nal_
Iv be { fe__,= v washmgttm warm soapy;wateE,,'._?,... ,
,-a, Dism( '_n:'_ _Otor .from the btcycte_anddramall-fuel
•from.the carburetor, fuel.tank an_ fuel hne+,.,;,..-, ......
-b Remove the spark plug;and place afew drops-of.motor
several t_mes and replacethe'spark"plug_+_ v: :'-°S .....
....=_.c.-Take'"sCecial ca_:e in'_leaning :the'uhit; and coat+_all bare
metal or plated parts with lSroper:anti-corrosion oil.
_d:."Stor'e the'Unit'in adry,'dust-free::place.¢-_:,:'. "'_"': r::HF
-FUELSYSTEM
,Check
'__:it may ¢auseshort circuit: .......
:::OVERHEATING : i: .... : - .
:Checkthe_f0]loWingand Correctif necessary: ' : : :::;
•°,i_*,:••iThefuel. rnixtureshouid bel.25 par_,reguta r gasR!!ne: _i..
:<""_:mix:ture will :result in :sever_arl_oni'zation' of :the coffi_; "''"
+ _bustion andexhaust areas an_cause overtieatirlg_ ::_; _'!_! _:
-ii+* i:When ignition timing is off'f+ro:m the fact6ni-set:stand -_:""
........_ard it will result: in: over tieati_g_ancl _u_e :po6r_pe_ "_ +'
formance. ..i:::_,;::+,_.,_,xy:,,.;_i::.
* When a high carbon buildup is noted in the.comb,s -':'_ "
tion or exhaust areas; the:_r_Sn::should_carefuliy 'be__;
removed. !:! .:! i i :. , ....... ,_-,_-;_i_.:i:;>:
;THEicARBURETOR AND FULLPUMP ARE'F;RELSET.AT THEFACTORY.ITHERE-I!;
FOR'-READJUSTMENT; OF._THESE INTEGRAL COMPON ENTS BY CuSToME RS IS _+i:
NOT'RECOMMENDED. FORSERVICE OTHER THAN THE PERIODICAL INSPEC-
TIONS CONTAINED IN THISilMANUAL, ALWAYS TAKE THE MOTOR TO ANY
SEARS SERVICE UNIT. " _:_!i_!/!-= -:.+::.:..........:,:_:.-+,:_-,;._.,.. _,.-::,-,:. ..,.,:,._+!
r

TROUBLESHOOTINGCHECK i
X .X
XX
X X, • X
X ,;::_: X
XX.... Xi:
X X
XXX X _,
X X .....'
x x:-'; x .i x
i
X ." X '':'X;I_ X' ':,:"X
xx:: ?i_:-xi::-x
x , x :.L,x x
XX X X
.......X .....-;.... X.........
your Bicycle Assist Motorlinto any one of over
2000 sears service units
' PushPrimeiPumptoPumpupFueli':;i:! '"__ " "
' • :FuelTankEmpty.- '_/i-__:_::--i_:,i__r '....
X'"i" FuelLineKinkedorPinched::iii ;_-L_,
. X: -Fuel FilterDid=or Clogged.... ,
X: Carburetor PassagesC!0ggedorDirty _<
|
X:<' ,WrongFuel-0ilMixture :-.
reto OfAdi
.ustment "'.... "
X,. --: Carbu rout , '
FuelFlooded -. .... " - , "
WrongTypeSparkPlug, :i _
"Defectiveor FoUledSparkPlug . ""
• •BreakerContactPointsOutofAdjustment
.., DefectiveMagneto - - .i . ,, •, .
_:-, : "-Spark DoesNotJumpSparkPlugGap •
X: " 'Outof Timing- ,:,
X BreakerContactpointsBurnedor,Pitted
XWeaklgnition'Coil;;::_"
Weak0r Defective'Condenser
" SparkPlugLeadWire NotSecured,., .... " ....
'Frayed0rCracked,LeadWire Insuiati'o0: • '_ ...... • -
Disconnected.Groundedor LooseWiringinElectricalSystem - ..... " '=_:_-._;
-X" i'";BolierSflps(NeedsadequatepresSure againsttire) _........ . .......+_:-_ _:....
.,. ,.
The parts list and drawings in the following contain all
the spare parts available for the FREE SPIRtT BICYCLE
ASSIST MOTOR. MODEL NO:, 298.488531 should
always be mentioned when ordering genuine spareparts
and also include the correct partnumber and the des-
cription. "
INSTRUCTIONS FOR THE PROPER USEOFTHIS
OWNERS MANUAL
1. ABBREVIATION : .-.
Thelfollowing abbreviations are used inthis manual.
COMP. (COMPLETE) ....... This referstoa part
made of two or more pieces; fixed together
permanentty, which connot be broken down.
ASS'Y (ASSEMBLY) " This refers to a part
made of two or more pieces, which can be
broken down to components.
HEX .............. HEXAGONAL
CONN ............. CONNECTING
MAG .............. MAGNETO
SCREW ........... ROUND HEAD SCREW
F. H. SCREW ........ COUNTER SUNK SCREW
WASHER .......... FLAT WASHER-
S: WASHER ........ SPRING (LOCK) WASHER
-,S: NUT " . SPECIALNUT
,"-_-:-. ............. The com ponent parts of an
2. DIMENSIONS -.....
All dimensions are in milimetres except for.special
fasteners, pulleys, steel balls,and wheels.
PART NAME .
PINor DOWELL::. .:.I.-
WASH ER.........;''
TUBE
PIN
"::" .6x150..i
6x12
OILSEAL
GASKET or O-RtNG
.... INTERPR ETA- :
EXAMPLE
.... -TION . i
5ramdiameter;• '
13ram length :,
foi:6mm fastener i
6mm inside dia- :
meter, L150mm
length. :
6ram diameter,
12ram length
12ram inside dia-
l2225 " meter, 22mm out-
side diameter 5mm:,
thick
'8 8rnm inside dia-
meter
• assembly. . .......
7

59
6
38
1-50, 990-11040-1Z1 "SCREW 4_12, ,-• ,
i-51 99Z-10040-012 S. WASHER 4:''
1-._,, 99Z-01040-011 W,,_.SH ._R.. 4
1-53 .990-11050-Z01 SCREW 5 x ZO
1..54 992-10050-01Z S. WASHER 5
z-ss z_z-oo_39-zo_"'PL_S_ P_
1-56 990-11040-081 SCREW 4x 8
1-57 99Z-100_O-01Z S. WASHER 4
1-58 992.01040-0._! WASHER 4,
: o .
1-60 751-O06Zw-ZO0 !SPECiALPACKING, MUFFLER
1-61 985-36150-900 ,,
970*36151-ZOZ
8

KEY.No! PARTS. _I _ _ P_ R T s _ _ i _ N _ M E " _ _ I_ 0'[_ _
'" - "'i"','" • '_ _,_ _ ", _:'i _ :,>'" -- ' "'" ' • _
'rio.2 cA.B"mo." .....'Ii
:2- I 716-00539-210 MUFFLER BODy'A' .... " :1
! 2- 2 717-00539-Z00 MUFFLE-..R. BODYB : I
'2. 3737-00539-200 MUFFLER GASKET .... .i [
:2. 4990-11050-381
2_ S ?5i-oo6ol-zoo
2-6 992-10050-012
2- 7990-11040-141
2. 8 992-10040-012
2. 9990-21060-201
Z*10 992-I0060-012
2-tl '990-21060-181
'2=12 i 992-i0060-012
2J13 220.)6100-210
2-14 680-3&I00-200
Z-1S 222-3`6100-Z10
"2-1`6 531-3`6150-800"
,z_i_ _3o-3`62oo-2oz
z_le 99z-oooso-oiz
,!2-19 992*90200*150
SCREWS X3s " " 2
MUFFLER S. GASKET '1
ScREW 4'_i4 '`6
S. WAS_ 4'6
BOLT `6 x20 1
S. WASHEP_ 6" |
BOLT 6 x18 " ' 1
S. WASHERs6 '_ ' " 1
MUFFLER P_PE 'I'
CLIP '" :' "Z
SUB_U_FL_ COMP ": ]
ADJUSTER ROD l:
S_ALL WASH]_R 5"'" I;
'SPLIT 'PIN .... I
WiNG NUT 6I
KEY.No.
2-21
2.22
2.2)
2-24
Z-25
2-2`6
Z-Z?
2-28
2_29
2L30
2-31
2-32
2-33
2-34
2-35
2-36
2_37
2_38
22_9
2-40
zZ_l
PARTS. Na . ' PARTS :: :. NAME '!' iO'ty
992-10060-012 S.' 'WASHE_ ,6 Z
99I-oio`6o-on i_v_6 ": '.......... ]
_O-)_lO0-ZOl SU._ MUP.C',_E.R STAY |
' ( • ' ", i
992-I0060-012 S. WASHER `6' 2
991-010`60-01i NUT `6 '''
403-00001-200 INLET MAN_FOLD GASKE?F 1
393_00005-202 INLI_T I'&.ANI FO.LD 1
990-11050-161 SCREW Sx16 2
992-iooso-ol:, s._AsHm__ z
455-22012-920 CARBURETOR ASS'y" !
CH KE0 ::
532-Z2012-200 LEVER CAP I
20Z-012Z5-200 GROMMET .... :1
704-36150.801 CHOKE BOTTON C()MP ;1
530-00564-200 RETUP.N PIPE I
NIL AIR CLEANER ASS*y (Refer to FIG. 6) 1
870-00005-930 THROTTLE LEVER ASS'Y 1
I70--OOS3SiaO0 LSTOP 'SWITCH" coMP i'
179-33411'-200 ' ' " "
STOP CORD COMP _1
Iva-oos)9-_i0 STOP'COR_COMP ' ' I
885-0056`6-800 THROTTLE WIRE COMP 1
2`6_-oos64-zoo'CXBLE __PROT_.CTOR'l
9

42 41 -
PUMP _
2
2
6
lO
FIG.3
19
20
30_
33
34
2
[28
29
28,
f
29
KEY.No. PARTS, No, PARTS " : j NAME 0"ty
3-33 113-36100-Z01 CLAMP STAY B . "I
3-34 99ZII0060-01Z S. WASHER 6 = .' _: " 6
3-35 990-1106O-ZSI SCREW 6"," Z5 "' ,6
3-36 401-3615e-Z01 FUEL'TANK , '; 1
3-37 6ZS-00S_9-ZO0 TANI__P" , .- . i.:
'S-_8 646-006ZC-Z00 AIR VENT VALVE ' { I-
B-39 6Zg-0062A*Z00 TANK INNF.R CAP { I
B-40 426-36151-Z00 COLLAR ' • { i
3-41 [8ZO-JZS00-Z00 WA_-HI:T_L 'l1
"_"' i_,-oo_o.-,oo_o_R _. " " ' :; ' { "-
3=45 990-I_050-isi {::SCRE'W._15 _:":'_'J_":-::"_'_. ' ! {Z:
BL,6 I675-o40oI-90o { POMP FILTER'Bi3Dy ASS'Y .... It I:'
' ':4' 1 680-04019-2-10" {'!'C_IP:7 t-:' :" '" '":" ': "'J_'' '1 111
3-48 678-0060t-Z01 :{ .RUBB_ PIPE " /, ..... ' , { IJ
3L49 _00*33Z0Z-ZO5 { R.UBBER CAP' ..... "}, K
S-S0 {595-01550-900 } PRIMER PUMP ASS'y ;. .... ,{ i:
3-51 700-03005-200 FUEL PIPE 3>" 5>" 200 { I_
_:_z _oo-o_oos-z_o! FUEL:,=,PE3-'S:.Z_0' . " {: i!
_-53 Z0O-005Bg-z_0 PUMP FIXING PLATE ,[1
3-% ,_9o-{zo4o-_61 { SCREW4x{6 ' _..., 'i . 1, B_.
3-57 99Z-10040-0iZ S. WASHER 4",,;:, ,. ' 3i.
3-58 991-01040-011 {NUT4 :!.3J
3_59 999-67004-000 { O-RING P-4 '11
_-60 611-o4ooi-Zl] { pUMPGASKE x ! . . : . ,1:
3-6Z 6:4-0_1001-ZII [ FRZE VAL_. , .1
3-63 66"_-00539-801 PUMP,SUGTION SIDE 1_
3*64 Z03-1030Z-201 GROMI_iET 11
3-65 669-00539-200 FUEL PIPE jOINT .... .I •
3-66 { 700-e_005-045 FUm:'LI:_pEJXSX45 :_: : :.;11

13
1
8
18
.k
29 15
16
17
2:
2
4
"/_ 11
10
9
733
FIG.4
25
26.2 27 28
(
(
KE' .No.1PARTS- No. PARTS NAME_ ': O'ty_
FIG.4 GEAR CASE -":':" /:
]!131-36100-Z01 GEAR CASE !:
2, 049-36100-200 GEAR. CASE COVER GASKET jl
3 999-616Z0-I00 BALL BEARING #6_0! J |"
4 015-35500-Z00 PROPELLER SHAFT SHIM 0.1 [i_3'
Ol&-355O0-ZO0 PROPELLER SHAFT SHIM 0. Z[ 1_3
02Z-35SOO-Z00 PROPELLER SHAFT SHIM 0.3 I I'_3
014.35500-200 PROPELLER SHAFT SHIM 1.0 J 1_--3
5 005-36100-204 GEAR _Yr'[AFT J ' !'
6068-00300-200 wOoD-RUFF KEY 5 x)0x3.7 j1
7017-36100-Z10 G_&R , " ' ]' I '
8993-Z4050-241 SPRING !_N A"I
9O! 5-35500-200 pROPELLER SHAFT SHIM 0;1 _ '1_3
016.35500-Z00 PROPELLER SbLAFT SHIM O+Z 1--3
0ZZ-35500-Z00 PROPELLER SHAFT _IM O. 31_3
014-35500-Z00 PROPELLER SHAFT ..SHIM 1.0 143
I0 999-61600=I00 BALI_ BEARING €6001 ' l
II 045-36f00-200 GEAR CASE COVER "I
|Z 992-10050-01Z S. WASHER 51
13 990-t1050-161 .SCREW 5 x16 .... 1
14 999-661ZZ-Z66 OIL SEAL 12227 1
•'L.. /. ....... _." • • L °
<EY:No. pARTS. N&
4-15 ,-z31.3610o-so0
4-16 99Z-IZOB0-01Z
4-17 _, 991-85080-3Z1
4-18"- 046-56100-Z00
4-i9..... 99z-loosoi&z
PARTS NAME
ROLLER COMP (No.48859)
S. WASHER 8
LONG NUT 8x32/L.H. SCREW
GEAR CASE GROMMET
s. WASHER 5
SCREW 5×14
BOLT 6 x 16
S, WASMER 6
GEAR CASE GASKET A
PINION
PROPELLER SHAFT SHIM 0. l
pROPELLER SHAFT SHIM o. 5
THRUST BEARING #10Z4
THRUST WASHER #1024
NEEDLE BEARING TLA 1010
ADAPTER COMP
TANK BRACKET
S. WASHER 5
SCREW 5x IZ
BRACKET
GROMMET
4-z0: ;990-11050-141
4-21 _990-Z1060-161
4_ZZ -'992-10060-012
4-23 "303.00ZO0=Z00
4-Z4'. 060=36100-Z10
4_25 ::064-35500-Z00
'063-35500-Z00
4-Z6-1 999-6_I02-463
4_26-2 999-6210Z-464
_-27 999-62101-010
-4-Z8 079-36100-802
4-Z9 4Z0-36150-800
4:30 99Z-lO050-01Z
,4231 990-II050-1Z!
4-32 390-36150-Z00
4-33 599-00601-Z00
O'ty
1
1
!
l
3
3
3
3
l
!
1
Z
Z
1
l
z
Z
1
I
11

19
10 9
\\\\\/
FIG.5
: i
12¸
, ::[[? •
KEY.N0,l PARTS, No, i PARTS "" NAME'' '.'" O'ty
'; ' - " ';, ....... ' ".?, i : i i
:" : FIG,S.ENGINE SHROUD & MARK
5_ I 380_36150-200
5-,2-i .990-i*oso-i41
5_ 3 99z-looso_olz
.5-,4. 992-010S0-011
5-5 •990_II050-141
5- 6, ' 992-10050-012
5-'7 992-01050-011
S-8 202o01003-201
5- 9990-11050o141
5-10 99Z-10050-012
5-11 99Z-01050-011
5112 580-3615l-Z00
5=13 .908_36"150-200
5-14 "9Z3;36150-Z00
5-i5 927-36150-Z00
5-16 920-36151-Z00
5-17 909_I1t08-20!
5-18 930-36151-200
5-19 933-36151-200
5-20 906-36151-200
EB;_IN E SHROUD :I
CSREW SXI4 .... I' i-
S. iWASHIER 5 ,. ,1
WASHER S:_1 1
SCREW 5 >, 14 , . Z-
S. !WASHER 5 ,1 ,Z,
WASHER5 ..... ,'ll
CROMMET .,..1
SCREW: 5 x t4 Z.
S[ WASHER S Z
WkSHERS .,.Z
CAUTION MARI_ SEARS 1
CI_OKE MARK ._I..
FUEL .LEVEL MARK _ .' 1
PRIMER _IARK "".|
SIDE },(ARK Z
TANK ]MARK ,!
SHROUD 1MARK Al,
SHROUD /_IARK B'1
NAME PLATH ,l

7
5
6
KEY.No] PARTS. Nc_' "i: PARTS 'NAME :O'ty
FIG.6 _-AIR CLEANER .... I
6- ! 424-00539-200 AIR,, CLEANER COVER Ii !
_' -6-3 _45.oo6oi-zoo_I CL_N_ ELE_E"T ' I l
s.5 '99z-ooo4o-oi:_I_AS_P.4 I 3 .
-'" 6- 6 990-11040-10| [ .SCREW 4 X10 ",_ I 3
'6- 8 990. I1040-101 SCREW 4x10 2
15
T6\
17_
21
FIG.7
KEY.N&I PARTs. N&
.FIG.7 CARBORETOR
7-0-1 4_S-22012-920
7- I ._.0-2260Z-200
7- Z597-2260E-200
?- _ 595-22602-200
?- 4 594;22000-200
?- 5 619-22602-200
7- 6 593-22000-200
7- 7 59z-2g012-ZI0
7-8 591-22009-Z00
7- 9 53O-220O9-800
7-10 623-22000-200
7-1! 622.22000-200
7-iz :591-22602-200
7-13 6t7-226OZ-2OO
?-14 992-01050-001
7-15 618-22602-200
7-16 607-Z2000-200
7-17 599-ZZOOO-Z52
7-21 580-22009-800
7-24 99Z-10:_40-012
7-25 990-11040-t01
7-26 526-22012-202
PARTS •NAME _ Q'ty
CARBURETOR ASS'Y 1
*RUBBER CAP l
*CABLE ADJUSTER ,l
*BODY CAP I
*THROTTLE VALVE SPRING 1
*THROTTLE SPRING RECEIVE 1
*3ET HEF_DLE CLIP !
*3ET NEEDLE 1
*THROTTLE VALVE 1
CARBURETOR BODY COMP I
ADJUST SPRING 1
- ADJUST SCREW ,I
*BAND 1
BAND BOLT I
*WA_ER 5!
* BODY BAND NUT
* CHAM.BER GASKET ]
*MAIN 3ET l
*FLOAT CHAMBER COA{P .:1
S. _A_-'IER 4". ' .
SCREW 4xI0 2
*COLLAR 1
13

MODEL NO.
298.488531
-,r,
HOW TO
- ORDER
..... REPLAC E MEN]:
PARTS
h
..... O
O
OWNER'S
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MANUAL:
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